CN112994375B - Motor manufacturing line and motor manufacturing method - Google Patents
Motor manufacturing line and motor manufacturing method Download PDFInfo
- Publication number
- CN112994375B CN112994375B CN202011473036.3A CN202011473036A CN112994375B CN 112994375 B CN112994375 B CN 112994375B CN 202011473036 A CN202011473036 A CN 202011473036A CN 112994375 B CN112994375 B CN 112994375B
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- stack
- stator
- pressurizing
- welding
- pressurization
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 74
- 238000003466 welding Methods 0.000 claims abstract description 97
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 17
- 239000010959 steel Substances 0.000 claims abstract description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000005259 measurement Methods 0.000 claims description 16
- 230000001678 irradiating effect Effects 0.000 claims 1
- 238000012546 transfer Methods 0.000 description 46
- 238000003475 lamination Methods 0.000 description 28
- 238000010586 diagram Methods 0.000 description 13
- 238000003825 pressing Methods 0.000 description 13
- 230000002950 deficient Effects 0.000 description 9
- 238000012790 confirmation Methods 0.000 description 8
- 238000000034 method Methods 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 238000006073 displacement reaction Methods 0.000 description 5
- 230000007246 mechanism Effects 0.000 description 4
- 238000004080 punching Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000012212 insulator Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 230000005389 magnetism Effects 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
- H02K15/026—Wound cores
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention provides a motor manufacturing line and a motor manufacturing method. The motor manufacturing line of the present invention comprises: a loading device that stacks a plurality of blocks formed by stacking a plurality of electromagnetic steel plates to form a stack; and a pressure welding device for forming the iron core by pressure welding the stack, the pressure welding device comprising: a table on which the stack is placed; a pressurizing unit that pressurizes the stack; and a laser irradiation unit that irradiates the stack with laser light, the pressurizing unit having: the stack is pressurized 1 st by a1 st pressurization value, then the 1 st pressurization is released, and the 2 nd pressurization is performed again by a2 nd pressurization value.
Description
Technical Field
The invention relates to a motor manufacturing line and a motor manufacturing method.
Background
In manufacturing a stator of a motor, conventionally, a stator block formed by stacking a plurality of laminated sheets (electromagnetic steel sheets) is mounted as a stator stack, and the stator blocks are welded to each other in a state where the stator stack is pressurized, thereby manufacturing a stator core.
Patent document 1: japanese patent application laid-open No. 2015-082848
However, after the stator core is manufactured, cracks may occur in the laser welded portions due to internal stress in each stator block. When cracks occur in the welded portions, the height dimension of the stator core changes, and the stator core becomes defective.
Disclosure of Invention
The motor manufacturing line according to one embodiment of the present invention includes: a loading device that stacks a plurality of blocks formed by stacking a plurality of electromagnetic steel plates to form a stack; and a pressure welding device for forming the iron core by pressure welding the stack, the pressure welding device comprising: a table on which the stack is placed; a pressurizing unit that pressurizes the stack; and a laser irradiation unit that irradiates the stack with laser light, the pressurizing unit having: the stack is pressurized 1 st by a1 st pressurization value, then the 1 st pressurization is released, and the 2 nd pressurization is performed again by a2 nd pressurization value.
One embodiment of the present invention is a motor manufacturing method for manufacturing a motor using the motor manufacturing line, wherein the motor manufacturing method includes: a loading step of stacking a plurality of blocks formed by stacking a plurality of electromagnetic steel plates to form a stack; a pressurizing step of pressurizing the stack; and a welding step of manufacturing an iron core by welding the stack, wherein the pressurizing step is performed sequentially by: a1 st pressurizing step of pressurizing the stack at a1 st pressurizing value; a pressurization releasing step of releasing pressurization of the 1 st pressurization value; and a2 nd pressurizing step of pressurizing the stack at a2 nd pressurizing value.
According to one embodiment of the present invention, a motor manufacturing line and a motor manufacturing method are provided that can suppress cracking at a welded portion of an iron core and improve yield.
Drawings
Fig. 1 is a diagram showing a stator manufacturing line of an embodiment.
Fig. 2 is a sectional view showing a structure of a general motor.
Fig. 3 is a perspective view showing a structure of a stator core according to an embodiment.
Fig. 4 is a diagram showing two blocks among a plurality of stator blocks constituting a stator core.
Fig. 5 is a diagram illustrating a portion of a stator manufacturing line of one embodiment.
Fig. 6 is a perspective view showing the structure of a pressure welding apparatus according to an embodiment.
Fig. 7 is a diagram showing a structure of a pressure welding apparatus according to an embodiment, and shows a state before pressurizing a stator stack.
Fig. 8 is a diagram showing a structure of a pressure welding apparatus according to an embodiment, and shows a state in which a stator stack is pressurized.
Fig. 9 is a diagram showing a structure of a pressure welding apparatus according to an embodiment, and shows a case of welding.
Fig. 10 is a view of the pressure welding apparatus according to the embodiment from above, and shows positions of a plurality of laser light irradiation portions.
Description of the reference numerals
1: a motor; 20: a stator; 23: stator core (iron core); 23A (23A 1, 23A 2): stator blocks (blocks); 23B: stator laminations (electromagnetic steel plates); 100: stator manufacturing line (motor manufacturing line); 108: a stator stack (pile); 210: a pressure welding device; 211a: a laser irradiation section; 212: a pressurizing section; 212B: a pressure sensor; 213: indexing tables (tables); 217: a height measurement sensor.
Detailed Description
In the drawings, an XYZ coordinate system is appropriately shown as a three-dimensional orthogonal coordinate system. The X direction is a direction perpendicular to the Z direction. The Y direction is a direction perpendicular to both the X direction and the Z direction.
Stator manufacturing line
Fig. 1 is a diagram showing a stator manufacturing line 100 according to the present embodiment.
In the following description, a direction parallel to the up-down direction is referred to as a Z direction, a direction parallel to the conveying direction of the 1 st conveying device 120 to the stator block (block) 23A is referred to as an X direction, and a conveying direction of the 2 nd conveying device 180 to the stator stack (stack) 108 is referred to as a Y direction.
The stator manufacturing line (motor manufacturing line) 100 shown in fig. 1 is a part of a motor manufacturing line. The motor manufacturing line includes not only the stator manufacturing line 100 but also the rotor manufacturing line, and the stator 20 (fig. 2) and the rotor 10 (fig. 2) are manufactured in the respective manufacturing lines and combined, whereby the motor 1 (fig. 2) can be manufactured.
Motor >
Fig. 2 is a sectional view showing the structure of a general motor 1. Fig. 3 is a perspective view showing a structure of a stator core (iron core) 23 according to an embodiment. Fig. 4 is a diagram showing 2 blocks among a plurality of stator blocks 23A constituting the stator core 23.
First, a structure of a motor 1 (fig. 2) having a stator 20 (fig. 2) manufactured by a stator manufacturing line 100 of the present embodiment shown in fig. 1 will be described.
The motor 1 is mounted on a vehicle such as a Hybrid Electric Vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or an Electric Vehicle (EV) that uses the motor as a power source, and is used as a power source for these vehicles. As shown in fig. 2, the motor 1 is mainly composed of a rotor 10, a stator 20 surrounding the rotor 10, and a housing 30.
(rotor)
The rotor 10 rotates about a central axis J1 extending in one direction. The rotor 10 has a shaft 21 extending along the central axis J1, a rotor core 12, and rotor magnets.
The rotor core 12 is constituted by a plurality of rotor blocks stacked in the axial direction. Each rotor block has a plurality of rotor laminations (electromagnetic steel plates) stacked in the axial direction. The rotor lamination is formed by punching out a thin steel plate having magnetism into a predetermined shape.
(stator 20)
As shown in fig. 2, the stator 20 is disposed radially outward of the rotor 10 and radially opposed to the rotor 10. The stator 20 includes a stator core 23, a plurality of insulators, and windings 24 attached to the insulators. The stator 20 is fixed to the inside of the housing 30 so as to surround the rotor 10 in an annular shape.
As shown in fig. 2 and 3, the stator core 23 includes a plurality of bolt fastening portions 23b protruding radially outward from the outer peripheral surface 23a. In the present embodiment, 4 bolt fastening portions 23b are arranged at equal intervals in the circumferential direction of the stator core 23. The stator core 23 is fixed to the housing 30 by bolts 92 inserted into bolt through holes 23c formed in the bolt fastening portions 23b.
As shown in fig. 3 and 4, the stator core 23 is constituted by a plurality of stator pieces 23A stacked in the axial direction. Each stator block 23A has a plurality of stator laminations 23B (electromagnetic steel plates) stacked in the axial direction. The stator lamination 23B is formed by punching out a thin steel plate having magnetism into a predetermined shape.
The stator core 23 is composed of two types of stator blocks 23A1, 23A2. The number of stator laminations 23B of the stator blocks 23A1, 23A2 is different. The 1 st stator block 23A1 is a block formed by stacking 35 stator laminations 23B, for example. On the other hand, the 2 nd stator block 23A2 is composed of stator laminations 23B having a smaller number of pieces (less than 35 pieces) than the 1 st stator block 23A1.
The number of lamination layers of the stator lamination 23B constituting the stator core 23 varies depending on the model of the motor 1, but in this example, 14 1 st stator pieces 23A1 and 2 nd stator pieces 23A2 are laminated together as 16 stator pieces in total as the stator core 23 shown in fig. 3, for example.
As shown in fig. 4, 8 welded portions 23C are formed at equal intervals in the circumferential direction, for example, on the outer circumferential surface side of the stator block 23A, and in the stator core 23 shown in fig. 3, the welded portions 23C of the stator blocks 23A arranged one above the other are welded in a straight line.
Stator manufacturing line 100 >
Next, a schematic structure and operation of the stator manufacturing line 100 will be described.
Fig. 5 is a diagram illustrating a portion of a stator manufacturing line 100 of one embodiment. Fig. 6 is a perspective view showing the structure of the pressure welding apparatus 210 according to one embodiment. Fig. 7 is a diagram showing the structure of the pressure welding apparatus 210 according to one embodiment, and shows a state before the stator stack 108 is pressurized. Fig. 8 is a diagram showing a structure of a pressure welding apparatus 210 according to an embodiment, and shows a state in which the stator stack 108 is pressurized. Fig. 9 is a diagram showing the structure of the pressure welding apparatus 210 according to one embodiment, and shows a case in welding. Fig. 10 is a diagram of the pressure welding apparatus 210 according to the embodiment, as viewed from above, and shows positions of a plurality of laser light irradiation portions.
As shown in fig. 1, the stator manufacturing line 100 includes a press working machine (stator block manufacturing apparatus) 110, a1 st transfer apparatus 120, a separating apparatus 130, a turning apparatus 140, a1 st transfer apparatus 150, a weight measuring apparatus 160, a rotary stacking apparatus (loading apparatus) 170, a2 nd transfer apparatus (transfer apparatus) 180, a2 nd transfer apparatus (transfer apparatus) 190, a pressure welding apparatus 210, a discharge apparatus 230, a height measuring apparatus (measuring apparatus) 220, and a dispensing apparatus 240.
(press working machine)
The press working machine 110 uses a press die to punch out stator laminations 23B having a predetermined shape from a magnetic thin steel plate, and then stacks and tightens a predetermined number of stator laminations 23B in the press die to form a block.
In the press working machine 110 of the present embodiment, the same type of stator pieces 23A are manufactured two by two. That is, the 1 st stator block 23A1 (fig. 4) and the 2 nd stator block 23A2 (fig. 4) are manufactured two by two, and are carried out in a state of being stacked two by two. Specifically, first, 7 sets of 14 th stator pieces 1 st stator piece 23A1 in total are manufactured, and then 1 set of 2 nd stator pieces 23A2 in total are manufactured. In the press working machine 110 of the present embodiment, the manufacturing process is regarded as one cycle.
(1 st conveying device)
As shown in fig. 1, the 1 st conveying device 120 includes a conveying conveyor 121, and one end of the conveying conveyor 121 on the upstream side in the conveying direction is connected to the press working machine 110, and the other end on the downstream side is connected to the inverting device 140. The 1 st conveying device 120 conveys the stator block 23A manufactured in the press working machine 110 by two types by a conveying conveyor 121.
The conveying conveyor 121 has a width smaller than the diameter of the stator block 23A, and conveys the stator block 23A in a state where a part of the conveyed stator block protrudes to the outside. That is, in a state where the center of the stator block 23A coincides with the widthwise center position of the conveying conveyor 121, both side ends of the stator block 23A intersecting the conveying direction protrude from the conveying conveyor 121.
In the present embodiment, the 1 st conveying device 120 has the conveying conveyor 121, but may be a roller conveyor, a loader, a robot, or a combination thereof.
(cutting device)
The separating device 130 has a function of separating the 2 stator pieces 23A discharged from the press working machine 110 one by one, respectively. The separating device 130 is located near the center of the conveyance conveyor 121 in the longitudinal direction shown in fig. 1, and is located between the press working machine 110 and a turning device 140 described later.
(turning device)
The reversing device 140 is located at the downstream end of the conveying conveyor 121, and has a function of reversing the front and back sides of the stator block 23A manufactured by the press working machine 110 (fig. 1) and separated by the separating device 130 one by one.
(1 st transfer device)
The 1 st transfer device 150 has a function of transferring the stator block 23A from the inverting device 140 to the weight measuring device 160.
(weight measuring device)
The weight measuring device 160 is disposed near the inverting device 140 and on one side (+y side) in the width direction of the conveying conveyor 121. The weight measuring device 160 measures the weight of each stator piece 23A by type, and confirms the number of stator laminations 23B (fig. 4) constituting each stator piece 23A.
(rotating lamination device)
As shown in fig. 1, the rotary stacking apparatus 170 includes an articulated arm (robot arm) 171, a notch detecting section 172, a stacking section 173, a temporary placement table 174, and a discharge conveyor (discharge section) 175.
The rotary lamination device 170 has the following functions: based on the measurement result of the weight measuring device 160, stator pieces 23A for which the number of stator laminations 23B (fig. 4) is correct and stator pieces 23A for which the number of stator laminations is abnormal are allocated, and a predetermined number of stator pieces 23A with acceptable number of stator laminations are stacked to form the stator stack 108.
The discharge conveyor 175 is provided with one end side positioned in the movable region of the articulated arm 171, and discharges the stator block 23A having a weight outside the predetermined weight and a defective number of sheets in the weight measuring device 160.
Temporary placement table 174 is a table for temporarily retracting other stator blocks 23A that are conveyed after the number of stator blocks 23A determined to be defective in weight measuring device 160. In this example, for example, the weight measuring device 160 has a function of temporarily retracting the 1 st stator block 23A1, which is determined to be defective in weight and is discharged, and then the 2 nd stator block 23A2, which is conveyed. In the temporary placement stage 174 of the present example, for example, 2 nd stator pieces 23A2 can be temporarily placed.
As shown in fig. 1 and 5, the stacking portion 173 includes: a table 173A for placing a plurality of stator blocks 23A sequentially carried by the articulated robot 171; a cylindrical center guide 173B inserted into an inner diameter hole 23Aa (fig. 4) of each stator block 23A mounted on the table 173A; and a pair of shaft guides 173C disposed on both outer sides in the width direction of the table 173A.
In the stacking portion 173, the plurality of stator blocks 23A mounted on the table 173A can be configured to form the plurality of stator stacks 108 while suppressing positional displacement of the plurality of stator blocks 23A in the axial direction by the center guide 173B and suppressing positional displacement of the plurality of stator blocks 23A in the axial direction by the pair of axial guides 173C.
The pair of shaft guides 173C has a function of aligning positions in the shaft direction of the plurality of stator blocks 23A mounted on the table 173A. As shown in fig. 4, the stator block 23A has 4 bolt fastening portions 23b protruding radially outward, and the pair of shaft guides 173C has the following structure: of the plurality of bolt fastening portions 23b arranged at equal intervals in the circumferential direction, 2 bolt fastening portions 23b opposed in the radial direction are gripped from the outside, respectively. Thereby, the bolt fastening portions 23b of the stator blocks 23A stacked one above the other can be aligned in position with each other.
(2 nd conveying device)
As shown in fig. 5, the 2 nd conveying device 180 includes a conveying rail mechanism 181 and a conveying support 182. The conveyance support 182 supports the stacking unit 173 from below, and is configured to reciprocate in one direction (+y direction) along the guide rail 183 of the conveyance rail mechanism 181. The 2 nd transfer device 180 is provided with one end side positioned in the movable area of the articulated arm 171, and transfers the stator stack 108 to the 2 nd transfer device 190 side together with the stacking unit 173.
(2 nd transfer device)
As shown in fig. 5, the 2 nd transfer device 190 is disposed on the other end side of the 2 nd transfer device 180, that is, on the opposite side of the articulated robot 171 shown in fig. 1. The 2 nd transfer device 190 has the following functions: the stator stack 108 is transferred between the 2 nd conveyor 180 and the pressure welding device 210, and the stator core 23 is transferred between the pressure welding device 210 and the height measuring device 220.
The 2 nd transfer device 190 includes a transfer unit 191, a conveying unit 192, and a rail unit 193. The transfer unit 191 includes at least an air chuck unit 191A that holds the stator stack 108, an air cylinder 191B that opens and closes the air chuck unit 191A, and a lifting unit 191C that is configured by a single-axis robot that moves the air chuck unit 191A up and down.
Air chuck section 191A is a parallel open/close type air chuck mechanism having 4 grip sections 191A. The 4 grip portions 191a are interlocked with each other, and opened and closed in response to the operation of the cylinder 191B. Stator stack 108 and center guide 173B can be gripped together by the opening and closing operation of air chuck segment 191A. Such a transfer unit 191 is connected to the conveying unit 192 and is movable along the rail unit 193.
The 2 nd transfer device 190 of the present embodiment is configured to transfer the stator stack 108 with the center guide 173B inserted inside the stator stack 108 in order to suppress the occurrence of positional displacement of the stator block 23A in the radial direction when the stator stack 108 is transferred from the 2 nd transfer device 180 to the pressure welding device 210, but to remove the center guide 173B from the stator stack 108 and transfer only the stator stack 108 to the pressure welding device 210 when the stator stack 108 is transferred to the pressure welding device 210.
(pressure welding apparatus)
As shown in fig. 5, the pressure welding apparatus 210 is disposed near the 2 nd transfer apparatus 190, and is disposed adjacent to the rail portion 193 on one side (+x side) in the width direction near the center in the longitudinal direction of the rail portion 193. As described above, only the stator stack 108 is supplied to the pressure welding apparatus 210 via the transfer unit 191 that moves along the rail portion 193 of the 2 nd transfer apparatus 190.
As shown in fig. 6 to 9, the pressure welding apparatus 210 includes: an indexing table (table) 213 on which the stator stack 108 is placed; a pressurizing unit 212 that pressurizes the stator stack 108 on the split table 213; and a laser irradiation unit 211 that irradiates the stator stack 108 with laser light. The pressure welding apparatus 210 further has a height measurement sensor 217, a1 st inventory confirmation sensor 214, a2 nd inventory confirmation sensor 215, a float confirmation sensor 216, and a baffle 218.
The pressure welding apparatus 210 according to the present embodiment is an apparatus for manufacturing the stator core 23 shown in fig. 3 by pressurizing the stator stack 108 carried in by the 2 nd transfer apparatus 190 by the pressurizing section 212 and joining the stator pieces 23A to each other by the laser irradiation section 211.
As shown in fig. 6, the index table 213 is constituted by a top plate having a circular shape in plan view, and is rotatable about a rotation axis O1 extending in the up-down direction (Z-axis direction). The index table 213 includes: a pair of support stands 213A disposed at positions radially opposite to each other with the rotation axis O1 interposed therebetween; and a pair of positional deviation suppressing pins 213B provided on each support stand 213A.
The pair of misalignment suppressing pins 213B are pins that hold the stator stack 108 transferred without the center guide 173B and suppress misalignment of the stator blocks 23A constituting the stator stack 108 in the radial direction. The pair of positional deviation suppressing pins 213B extend in the up-down direction (Z direction) and are arranged at a predetermined interval from each other. The misalignment suppressing pins 213B are inserted into 2 bolt through holes 23c facing each other in the radial direction, out of the 4 bolt through holes 23c of the stator block 23A shown in fig. 3. With this configuration, the press welding can be performed while suppressing the misalignment of the stator pieces 23A of the stator stack 108 transferred to the press welding apparatus 210.
The index table 213 of the present embodiment is rotatable about the rotation axis O1 every 180 degrees. Therefore, each time the indexing table 213 is rotated, the position of each support table 213A can be alternately changed such that one support table 213A is disposed at the "carry-in/out position" of the stator stack 108 and the other support table 213A is disposed at the "press-welding position" of the stator stack 108. The left side in the drawing of the pair of support stands 213A illustrated in fig. 7 is the "carry-in/out position", and the right side in the drawing is the "press-welding position".
The "carry-in/out position" shown on the left side in fig. 7 is provided with a2 nd stock confirmation sensor 215 and a float confirmation sensor 216, which are constituted by transmission sensors.
The 2 nd stock confirmation sensor 215 is a sensor for detecting whether or not the stator stack 108 is present on the support stand 213A, and includes an irradiation portion 215a and a light receiving portion 215b disposed in the vicinity of the support stand 213A.
The float check sensor 216 is a sensor for checking whether or not the stator stack 108 mounted on the support stand 213A floats, and includes an irradiation portion 216a and a light receiving portion 216b. The float check sensor 216 is disposed slightly above the 2 nd inventory check sensor 215 and above the height dimension of the stator stack 108 mounted on the support stand 213A.
Thus, when the stator stack 108 is normally placed on the support stand 213A, the light emitted from the irradiation unit 216a is detected by the light receiving unit 216b, and when the stator stack 108 floats, the light from the irradiation unit 216a is blocked by a part of the stator stack 108. In this way, whether or not the stator stack 108 is lifted, that is, whether or not the stator stack 108 is placed on the support stand 213A is normal can be checked.
The above-described rotation of the index table 213 is performed in a state where the shutter 218 is opened. When the index table 213 is rotated, the shutter 218 needs to be opened in advance to prevent interference between the shutter 218 and the jig.
The shutter 218 shields the laser light generated during welding from leaking to the outside of the pressure welding apparatus 210. The shutter 218 also functions as a door when the stator stack 108 is supplied to the indexing table 213 or when the stator stack 108 is discharged from the indexing table 213.
On the other hand, the "pressure welding position" shown on the right side in fig. 7 is provided with a pressure portion 212, a plurality of laser light irradiation portions 211a (fig. 9), a height measurement sensor 217, and a1 st stock confirmation sensor 214.
As shown in fig. 7, the pressing portion 212 has the following functions: the stator stack 108 transferred to the support table 213A of the index table 213 is pressurized in the axial direction (-Z direction), and the stacked stator blocks 23A are pressed downward. The pressurizing unit 212 of the present embodiment is configured by a servo press unit 212A incorporating a pressure sensor 212B, and can control the pressurizing value for the stator stack 108 in each pressurizing operation. The pressure sensor 212B detects a value of pressurization to the stator stack 108.
As shown in fig. 7 and 8, the pressing portion 212 mainly includes: a servo motor (not shown); a servo press 212a having a crown 212a1 that moves up and down by driving of a servo motor; a slider 212b that slides downward by the load action generated by the servo punch 212 a; a pressing portion 212e disposed at a position facing one of the pair of support tables 213A on the index table 213 side in the vertical direction on the lower surface side of the slider 212 b; and a positioning shaft portion 212c that can be inserted into the inside of the stator stack 108.
As shown in fig. 8, the positioning shaft 212c is a shaft that moves up and down with the operation of the servo press 212a, and is configured to be inserted into the inner diameter hole 108b of the stator stack 108 through a through hole 212j that penetrates both the slider 212a2 and the pressing portion 212 e. The positioning shaft portion 212c is inserted into the inner diameter hole 108b of the stator stack 108 while the servo press machine 212a is lowered, whereby the stator pieces 23A in the stator stack 108 before press welding can be restrained from being displaced in the radial direction from each other.
As shown in fig. 7, the 1 st stock confirmation sensor 214 is located near the pressing surface 212e1 of the pressing portion 212e, and can confirm the presence or absence of the stator stack 108 at the "press welding position" by detecting the upper portion of the stator stack 108 at the time of pressing as shown in fig. 8.
The height measurement sensor 217 is a contact displacement sensor, and is provided on a leg 212g that supports the servo press 212a and the slider 212 b. The height measurement sensor 217 has the following functions: the height of the stator stack 108 is measured by contact with a contact portion 212h disposed on the lower surface side of the slider 212 b.
Specifically, the contact surface 212h1 of the contact portion 212h coincides with the position in the up-down direction (Z direction) of the pressing surface 212e1 of the pressing portion 212e, and the height measurement sensor 217 can indirectly detect the position of the upper end surface 108a of the stator stack 108 that the pressing surface 212e1 contacts by contacting the contact surface 212h1, and can measure the height of the stator stack 108.
The pressure welding apparatus 210 of the present embodiment has the following functions: measuring a height of the stator stack 108 before welding carried onto the index table 213 by the pressurizing unit 212 at a predetermined pressure; only highly qualified stator stacks 108 are welded.
The pressure welding apparatus 210 according to the present embodiment is configured to perform two-stage pressure welding on the stator stack 108 by the pressure portion 212. Specifically, the pressurizing portion 212 has the following functions: the 1 st pressurization is performed on the stator stack 108 at the 1 st pressurization value, then the 1 st pressurization is temporarily released, and the 2 nd pressurization is performed again at the 2 nd pressurization value.
As shown in fig. 6, the laser irradiation section 211 includes: a pair of irradiation units 211A opposed to each other with a rotation axis O2 extending in the up-down direction (Z direction) interposed therebetween; a pair of lifting portions 211B that move each irradiation unit 211A in the up-down direction; and a pair of rotation portions 211C that rotate each of the irradiation units 211A about the rotation axis O2.
As shown in fig. 10, each irradiation unit 211A has 2 laser irradiation parts 211A, and the irradiation support part 211b supports the 2 laser irradiation parts 211A. The irradiation units 211A can be moved up and down by the operation of the lifting/lowering unit 211B formed by the single-axis robot, and the operations are synchronized with each other. In the present embodiment, welding can be performed upward from the lower end side of the stator stack 108.
The laser irradiation sections 211 have a total of 4 laser irradiation sections 211a, and are disposed at equal intervals around the stator stack 108. The 4 laser irradiation portions 211a can simultaneously irradiate the welding portions 23C of 4 out of the welding portions 23C (fig. 10) of 8 portions of the outer peripheral surface of the stator stack 108 (each stator piece 23A). As will be described later, in the present embodiment, the laser beam can be irradiated to the welding portion 23C of 8 total parts of 4 parts at a time twice.
The irradiation unit 211A described above can be rotated about the rotation axis O2 by the operation of the rotation portion 211C constituted by a cylinder. The irradiation units 211A may be configured to be rotatable about an axis with at least 2 laser irradiation units 211A being arranged at intervals.
Therefore, after the 1 st irradiation is performed on the 4 laser irradiation portions 211a, the 4 laser irradiation portions 211a are rotated about the rotation axis O2 by a predetermined angle, respectively, whereby the laser light can be irradiated to the welding portions 23C of the remaining 4 portions.
The irradiation unit 211A is not limited to the one rotating around the rotation axis O2, and may be configured as follows: by the operation of the cylinders, each irradiation unit 211A is linearly moved along the horizontal direction intersecting the emission direction, and thereby irradiates the other welding portion 23C with laser light.
(discharge device)
The discharge device 230 is a device that discharges the unwelded stator stack 108 that is highly disqualified in the pressure welding device 210. The discharge device 230 includes a discharge table 231 and a discharge rail portion 232 connected to the discharge table 231. As shown in fig. 1 and 5, the discharge device 230 is disposed near the 2 nd transfer device 190, and is disposed adjacent to the rail portion 193 on the other end side of the rail portion 193 on the width direction side (+x side). The discharge device 230 of the present embodiment discharges the unwelded stator stack 108 transferred from the pressure welding device 210 by the 2 nd transfer device 190.
(height measuring apparatus)
As shown in fig. 1, the height measuring device 220 measures the height of the press-welded stator core 23 transferred by the 2 nd transfer device 190. The height measuring device 220 is disposed downstream of the pressure welding device 210 in the conveying direction and at a position on the rear end side of the rail portion 193 of the 2 nd transfer device 190, and is disposed adjacent to the pressure welding device 210 on one side (+x side) in the width direction of the rail portion 193.
(dispensing device)
The distribution device 240 is a device for dividing the stator core 23 into good and defective products based on the measurement result of the height measurement device 220. As shown in fig. 5, the dispensing device 240 includes a conveying conveyor 242 that conveys the good stator core 23, a discharge conveyor 243 that discharges the defective stator core 23, and a pushing mechanism 244 that pushes the stator core 23 to any one of the conveying conveyor 242 and the discharge conveyor 243.
Thus, the stator manufacturing line 100 of the present embodiment is configured.
Stator manufacturing method (motor manufacturing method) >, stator manufacturing method, and motor manufacturing method
Next, a method of manufacturing the stator core 23 using the stator manufacturing line 100 according to the present embodiment described above will be described. In the following description, reference is made to fig. 1 to 10 as appropriate.
(1. Stator block manufacturing Process)
First, in the press working machine 110 of the stator manufacturing line 100 shown in fig. 1, a plurality of stator laminations 23B having a predetermined shape are punched out of a flat steel plate by a die, and each of the plurality of laminated stator laminations 23B is swaged to each other, whereby 2 stator pieces 23A are manufactured at a time.
At this time, the 1 st stator block 23A1 was produced using the stator laminations 23B each of which was laminated with 35 pieces, and a total of 14 pieces were produced successively 2 pieces at a time.
Next, using the stator lamination 23B having a smaller number of sheets (less than 35 sheets) than the 1 st stator block 23A1, the 2 nd stator block 23A2 is manufactured by one caulking process. Thus, a total of 16 stator pieces 23A required for manufacturing 1 stator core are manufactured at a time.
The stator block 23A manufactured in the press working machine 110 is carried out in a state of being stacked one by the conveyance conveyor 121 of the 1 st conveyance device 120.
(2. Cutting step)
Next, the 2 stator blocks 23A stacked one above the other are separated one by a separating device 130 provided on the conveying conveyor 121.
(3. Stator block turning step)
Then, the reversing device 140 reverses the front and back of each stator block 23A.
The stator block 23A released from the press working machine 110 has burrs on the opposite side to the lower side in the punching direction. In the case of inserting the component into the stator core in the subsequent winding step, burrs may become an obstacle, and therefore, in view of this, the reverse surface 23Ab, which is the lower side in the punching direction of the stator block 23A, is directed upward in the stage of the stator core manufacturing step.
(4. Stator Block transfer Process)
Next, the 1 st transfer device 150 shown in fig. 1 picks up the stator piece 23A flipped in the flipping device 140 from the flipping device 140 and transfers it to the weight measuring device 160.
(5 weight measurement step)
Next, the weight of each stator block 23A is measured by the weight measuring device 160.
The number of stator laminations 23B constituting each of the 1 st stator block 23A1 and the 2 nd stator block 23A2 is checked by measuring the weight of each stator block 23A and comparing the measurement result with a predetermined weight for each block type.
In the case of the 1 st stator block 23A1, it was checked whether or not the measurement result corresponds to the weight of the 35 stator laminations 23B, and it was determined whether or not the number of lamination components was correct as the 1 st stator block 23A1.
In the case of the 2 nd stator block 23A2, it was checked whether the measurement result corresponds to the weight when the number of stator laminations 23B is 35 or less, and it was determined whether the number of lamination components was correct as the 2 nd stator block 23A2.
In this example, the weight of 14 1 st stator pieces 23A1 continuously conveyed is measured first, and then the weight of 2 nd stator pieces 23A2 is measured.
(6. Rotating lamination step)
Next, the multi-joint robot 171 shown in fig. 1 moves the stator block 23A, the number of which is determined to be correct by measuring the weight, to the notch detecting section 172.
The notch detection unit 172 confirms the position of the notch 23Ad formed on the outer peripheral side of the stator block 23A (fig. 3 and 4), and then transfers the stator block 23A to the table 173A of the stacking unit 173. In this example, the multi-joint robot 171 rotates each stator block 23A by 90 degrees according to the position of the notch 23Ad, and stacks the stator blocks.
After the stator block 23A is placed on the table 173A shown in fig. 5, the center guide 173B is lifted from the through hole formed in the center of the table 173A, and enters the inside diameter hole 23Aa (fig. 4) of the stator block 23A on the table 173A. At this time, the front end position of the center guide 173B is made not to protrude from the upper surface of the stator piece 23A, so that stacking of the next stator piece 23A is easy.
In this example, the center guide 173B is raised one stage each time the stator block 23A is stacked on the table 173A. This eliminates the positional displacement in the radial direction of the stacked stator blocks 23A, and enables stacking in the up-down direction (+z direction) while being aligned with the position of the stator block 23A on the lower stage side.
Thus, after 14-stage 1 st stator pieces 23A1 are stacked, 2-stage 2 nd stator pieces 23A2 are stacked, and a total of 16-stage stator pieces 23A are stacked to form a stator stack.
On the other hand, the articulated robot 171 discharges the stator block 23A determined to be defective in the number of sheets in the weight measuring device 160 by the discharge conveyor 175 (fig. 1).
In this example, when the 1 st stator block 23A determined to be unqualified in the weight measuring device 160 is excluded, the 1 st stator blocks 23A that are transported later are stacked in order. The number of stacked stages is a number of stages smaller than the number of discharged 1 st stator pieces 23A1.
At this time, since the number of the 1 st stator blocks 23A1 stacked is less than 14 stages, the 2 nd stator block 23A2 conveyed next is temporarily retracted to the temporary placement stage 174.
In the press working machine 110 of the present embodiment, since 14 1 st stator pieces 23A1 are continuously produced and 2 nd stator pieces 23A2 are continuously produced, even when one 1 st stator piece 23A1 is found to be abnormal and discharged, the number of 1 st stator pieces 23A1 required for producing the stator stack 108 becomes insufficient.
When 1 st stator block 23A1 is discharged, after 13-stage 1 st stator blocks 23A1 having a satisfactory number of pieces are stacked, the 2 nd stator blocks 23A2 next are moved to the temporary placement stage 174, and the 1 st stator blocks 23A1 in the number that is missing are filled from the next cycle.
After the 1 st stator block 23A1 having a number of 14 stages qualified is stacked, the 2 nd stator block 23A2 for height adjustment retracted to the temporary placement table 174 is stacked thereon for 2 stages, whereby a total of 16 stages of stator blocks 23A are stacked. Thus, the stator stack 108 satisfying a predetermined height is manufactured.
Next, the manufactured stator stack 108 is lifted up together with the center guide 173B by the 2 nd transfer device 190, and transferred in the transfer direction (+y direction) to the pressure welding device 210. At this time, the 2 nd transfer device 190 transfers the stator stack 108 together with the center guide 173B, but transfers only the stator stack 108 to the pressure welding device 210. The center guide 173B is removed from the stator stack 108 by the 2 nd transfer device 190, and returned to the 2 nd transfer device 180.
(7. Pressure welding step)
First, the pressure welding apparatus 210 checks whether or not the stator stack 108 is transferred to one support table 213A of the index table 213, that is, the support table 213A on the "carry-in/out position" side, by the 2 nd inventory check sensor 215 in a state where the shutter 218 shown in fig. 7 is opened. After confirming that the stator stack 108 is present on the support stand 213A, the index table 213 is rotated 180 degrees, and the stator stack 108 is moved to the "press welding position". When the rotation of the index table 213 is completed, the shutter 218 is closed.
(7-1. Step 1 of pressurizing)
Then, the servo press 212a of the pressing unit 212 is lowered to press the stator stack 108 at the 1 st pressing value. In the present embodiment, the stator stack 108 is pressurized at 17kN, for example, as the 1 st pressurization.
(7-2. Pressurization releasing step)
After confirming that the 1 st pressurization value is 17kN by the pressure sensor 212B, the servo press 212a is raised to temporarily release the pressurization to the stator stack 108.
(7-3. Step 2 of pressurizing)
Then, the stator stack 108 is pressurized again by the servo punch 212a at the 2 nd pressurization value. In the present embodiment, the stator stack 108 is pressurized at 8.6kN, for example, as the 2 nd pressurization. After confirming that the 2 nd pressurization value is 8.6kN by the pressure sensor 212B, the height dimension of the stator stack 108 in the pressurized state is measured by the height measurement sensor 217.
As a result, when the height dimension of the stator stack 108 at the time of pressurization is outside the predetermined dimension, the welding is not performed and the stator stack is discharged. Specifically, the index table 213 is rotated to move the stator stack 108 having a defective height to the "carry-in/out position", and the 2 nd transfer device 190 transfers the stator stack from the pressure welding device 210 to the discharge device 230. In this way, the defective stator stack 108 is discharged in an unwelded state.
(7-4. 1 st welding Process)
On the other hand, welding is performed on the highly qualified stator stack 108 in a pressurized state. The laser irradiation section 211 irradiates laser light to 4 welded portions 23C among the welded portions 23C provided at 8 portions of the outer periphery of the stator stack 108 first by 4 laser irradiation sections 211a. In the present embodiment, welding is performed in a straight line from the lower end side to the upper side.
(7-5. 2. Welding Process)
When the 1 st welding process is completed, the 4 laser irradiation units 211a moved to the upper end side of the stator stack 108 are lowered again by the raising and lowering unit 211B, and the laser irradiation units 211a are rotated about the rotation axis O2 by the rotation unit 211C by a predetermined angle θ (for example, 45 degrees: fig. 10) to move the positions, and the welding units 23C of the remaining 4 portions are irradiated with laser light. At this time, welding is also performed from the lower end side toward the upper end side of the stator stack 108. In this way, the plurality of stator pieces 23A constituting the stator stack 108 are welded to each other to manufacture the stator core 23.
Next, after the shutter 218 is opened, the indexing table 213 is rotated 180 degrees, and the manufactured stator core 23 is moved from the "press welding position" to the "carry-in/out position".
Then, the servo press 212a is raised to release the pressing force on the stator core 23.
Next, the 2 nd transfer device 190 transfers the pressure welding device 210 to the height measuring device 220. After the height of the welded stator core 23 is measured by the height measuring device 220, the stator core is transported to a subsequent manufacturing process place by the transport conveyor 242.
As described above, in the stator manufacturing line 100 according to the present embodiment, the 1 st pressurization (17 kN), the pressurization release, and the 2 nd pressurization (8.6 kN) are sequentially performed before the laser welding of the stator stack 108 in the pressurization welding device 210, so that the internal stress in the stator stack 108 due to the caulking failure or the like of each stator piece 23A is reduced. In the present embodiment, the stator stack 108 is intermittently pressurized twice and the 2 nd pressurization is performed at a pressure smaller than the pressurization value at the time of the first pressurization 1, whereby the internal stress in the stator stack 108 can be reduced more effectively, and the occurrence of cracks or the like in the welded portion after the welding process can be suppressed.
In the present embodiment, the 1 st pressurization value is 17kN, and the 2 nd pressurization value is 8.6kN, but the present invention is not limited thereto. As long as at least the 2 nd pressurization value is smaller than the 1 st pressurization value, the internal stress of the stator stack 108 can be reduced. In addition, by making the 2 nd pressurization value about half the 1 st pressurization value, the internal stress of the stator stack 108 can be reduced more effectively.
The pressure welding apparatus 210 of the present embodiment has a servo press unit 212A incorporating a pressure sensor 212B, and can perform pressure control simply and accurately at the 1 st pressure and at the 2 nd pressure, which have different pressure values.
In addition, the pressure welding apparatus 210 of the present embodiment measures the height of the stator stack 108 at the time of the 2 nd pressurizing before welding the stator stack 108. By measuring the height at the time of the 2 nd pressurization and discharging the stator stack 108 without performing welding, it is possible to eliminate wasteful welding processing, and to improve the manufacturing efficiency and reduce the manufacturing cost.
As described above, the pressure welding apparatus 210 performs the welding process only on the stator stack 108 determined to be highly qualified, and at this time, performs the welding while maintaining the predetermined height in a state where the stator stack 108 is pressurized at the 2 nd pressurizing value. This makes it possible to manufacture the stator core 23 having a predetermined height, and the yield is improved.
While the embodiments of the present invention have been described above, the configurations and combinations thereof in the embodiments are examples, and the configurations may be added, omitted, substituted, and other modifications without departing from the scope of the present invention. The present invention is not limited to the embodiments.
The stator manufacturing line 100 of the present embodiment is also applicable to a rotor manufacturing line, and can manufacture a rotor core.
Claims (9)
1. A motor manufacturing line, comprising:
a weight measuring device for measuring the weight of a block formed by stacking a plurality of electromagnetic steel plates to confirm the number of the electromagnetic steel plates;
a loading device that stacks a plurality of the pieces of the electromagnetic steel sheet that are qualified in number to form a stack;
a pressure welding device for forming an iron core by pressure welding the stack, the pressure welding device having a function of measuring a height of the stack when the stack is pressurized before welding; and
a measuring device for measuring the height of the iron core,
the pressure welding device comprises:
a table on which the stack is placed;
a pressurizing unit that pressurizes the stack; and
a laser irradiation unit for irradiating the stack with laser light,
the pressurizing part has the following functions: pressurizing the stack 1 by a1 st pressurizing value, then releasing the 1 st pressurizing, pressurizing 2 by a2 nd pressurizing value again,
in this motor manufacturing line, it is determined whether the number of pieces of the electromagnetic steel sheet of the block, the height of the stack before welding, and the height of the core are acceptable or not, based on the measurement results of the weight measuring device, the pressure welding device, and the measuring device, in order, and the block whose number of pieces of the electromagnetic steel sheet is unacceptable, the stack before welding whose height is unacceptable, and the core whose height is unacceptable are discharged, respectively.
2. The motor manufacturing line according to claim 1, wherein,
the pressurizing section has:
a pressure sensor that detects a pressurization value for the stack; and
a height measurement sensor that measures the height of the stack when pressurized.
3. The motor manufacturing line according to claim 1 or 2, wherein,
the laser irradiation section has the following functions: welding the stack pressurized by the pressurizing section at the 2 nd pressurizing value.
4. The motor manufacturing line according to claim 1 or 2, wherein,
the 2 nd pressurization value is smaller than the 1 st pressurization value.
5. The motor manufacturing line according to claim 4, wherein,
the 2 nd pressurization value is half of the 1 st pressurization value.
6. A motor manufacturing method for manufacturing a motor using the motor manufacturing line according to any one of claims 1 to 5, wherein,
the motor manufacturing method comprises the following steps:
a loading step of stacking a plurality of blocks formed by stacking a plurality of electromagnetic steel plates to form a stack;
a pressurizing step of pressurizing the stack; and
a welding step of manufacturing an iron core by welding the stack,
in the pressurizing step, the following steps are sequentially performed:
a1 st pressurizing step of pressurizing the stack at a1 st pressurizing value;
a pressurization releasing step of releasing pressurization of the 1 st pressurization value; and
and a2 nd pressurizing step of pressurizing the stack at a2 nd pressurizing value.
7. The motor manufacturing method according to claim 6, wherein,
the height of the stack is measured in the 2 nd pressurizing step,
in the welding step, welding is performed only on the stack that satisfies a predetermined height condition, and welding is performed in a state where the stack is pressurized at the 2 nd pressurizing value.
8. The motor manufacturing method according to claim 6 or 7, wherein,
the 2 nd pressurization value is smaller than the 1 st pressurization value.
9. The motor manufacturing method according to claim 8, wherein,
the 2 nd pressurization value is half of the 1 st pressurization value.
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| CN114571048A (en) * | 2022-03-16 | 2022-06-03 | 刘东锋 | Stator punching lamination and welding integrated equipment |
| CN114499076A (en) * | 2022-03-21 | 2022-05-13 | 苏州天弘激光股份有限公司 | Processing method of motor stator |
| JP2024054602A (en) * | 2022-10-05 | 2024-04-17 | 株式会社三井ハイテック | Manufacturing apparatus of laminate, manufacturing system of motor core, and manufacturing method of laminate |
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| JP2006081378A (en) * | 2004-09-13 | 2006-03-23 | Mitsui High Tec Inc | Manufacturing method of laminated core and manufacturing apparatus thereof |
| JP2019033595A (en) * | 2017-08-08 | 2019-02-28 | 東芝産業機器システム株式会社 | Iron core manufacturing apparatus and iron core manufacturing method |
| WO2019058703A1 (en) * | 2017-09-25 | 2019-03-28 | 日本電産株式会社 | Method for producing steel sheet stacked body, and moulded steel sheet stacked body |
| CN109728689A (en) * | 2019-01-16 | 2019-05-07 | 南京埃斯顿自动化股份有限公司 | A kind of stator spelling circle equipment of centralization winding servo motor |
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| JP2006081378A (en) * | 2004-09-13 | 2006-03-23 | Mitsui High Tec Inc | Manufacturing method of laminated core and manufacturing apparatus thereof |
| JP2019033595A (en) * | 2017-08-08 | 2019-02-28 | 東芝産業機器システム株式会社 | Iron core manufacturing apparatus and iron core manufacturing method |
| WO2019058703A1 (en) * | 2017-09-25 | 2019-03-28 | 日本電産株式会社 | Method for producing steel sheet stacked body, and moulded steel sheet stacked body |
| CN109728689A (en) * | 2019-01-16 | 2019-05-07 | 南京埃斯顿自动化股份有限公司 | A kind of stator spelling circle equipment of centralization winding servo motor |
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